Consumable for use with apparatus for heating aerosolisable material

ABSTRACT

Described herein is a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable comprising a hollow tube comprising a wound structure comprising aerosolizable material.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No. PCT/EP2019/070735, filed Jul. 31, 2019 which claims priority from GB Patent Application No. 1812492.5 filed Jul. 31, 2018, each of which is hereby fully incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to consumables for use with apparatus for heating aerosolizable material, to systems comprising such a consumable and an apparatus for heating aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material, and to methods of manufacturing consumables for use with apparatus for heating aerosolizable material.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting. Examples of such products are so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

SUMMARY

A first aspect of the present disclosure provides a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable comprising a hollow tube comprising a wound structure comprising aerosolizable material.

In an exemplary embodiment, the consumable is non-combustible.

In an exemplary embodiment, the wound structure is a helically wound structure.

In an exemplary embodiment, the aerosolizable material comprises tobacco. In an exemplary embodiment, the aerosolizable material comprises reconstituted aerosolizable material. In an exemplary embodiment, the aerosolizable material comprises an amorphous solid.

In an exemplary embodiment, the structure comprising aerosolizable material comprises a carrier, and the aerosolizable material is on a surface of the carrier or impregnated in the carrier. In an exemplary embodiment, the structure comprising aerosolizable material consists of the aerosolizable material. For example, the aerosolizable material may be cast or otherwise shaped.

In an exemplary embodiment, the wound structure comprising aerosolizable material defines at least part of a surface of the consumable. In an exemplary embodiment, the wound structure comprising aerosolizable material defines the surface of the consumable. In an exemplary embodiment, the surface is an innermost surface of the consumable.

In an exemplary embodiment, the wound structure comprising aerosolizable material comprises corrugations, embossing or debossing.

In an exemplary embodiment, the wound structure forms a layer of the hollow tube, and the hollow tube comprises one or more further layers. In an exemplary embodiment, at least one of the further layer is a wound layer, such as a helically wound layer. In an exemplary embodiment, the aerosolizable material adheres the wound structure comprising aerosolizable material to at least one of the one or more further layers.

In an exemplary embodiment, the wound structure comprising aerosolizable material comprises corrugations, embossing or debossing, and the hollow tube comprises one or more aerosol flow paths defined by and between the corrugations, embossing or debossing of the structure comprising aerosolizable material and at least one of the one or more further layers.

In an exemplary embodiment, the hollow tube comprises a barrier layer that defines at least part of a surface of the consumable. In an exemplary embodiment, the barrier layer is impermeable to aerosol released from the aerosolizable material during heating of the aerosolizable material in use. In an exemplary embodiment, the barrier layer is a wound layer, such as a helically wound layer. In an exemplary embodiment, the barrier layer defines the surface of the consumable. In an exemplary embodiment, the surface is an outermost surface of the consumable.

In an exemplary embodiment, the consumable is free from heating material that is heatable by penetration with a varying magnetic field. In an alternate exemplary embodiment, the consumable comprises heating material that is heatable by penetration with a varying magnetic field. In an exemplary embodiment, the hollow tube comprises a layer comprising the heating material.

In an exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of: an electrically-conductive material, a magnetic material, and a magnetic electrically-conductive material. In an exemplary embodiment, the heating material comprises a metal or a metal alloy. In an exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain-carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

In an exemplary embodiment, the layer comprising the heating material comprises a metal foil or a metal alloy foil.

In an exemplary embodiment, the layer comprising the heating material is a wound layer, such as a helically wound layer.

In an exemplary embodiment, the hollow tube comprises a barrier layer that defines at least part of a surface of the consumable, and the layer comprising the heating material is located between the barrier layer and the wound structure comprising aerosolizable material.

In an exemplary embodiment, the layer comprising the heating material is located radially outwards of the wound structure comprising aerosolizable material.

In an exemplary embodiment, the one or more further layers comprise one or more further wound layers, such as helically wound layers.

In an exemplary embodiment, the hollow tube comprises one or more further layers, and at least one of the one or more further layers comprises aerosolizable material. In an exemplary embodiment, the hollow tube comprises a layer comprising heating material, wherein the layer comprising heating material is located between the wound structure comprising aerosolizable material and the at least one further layer comprising aerosolizable material.

In an exemplary embodiment, the hollow tube comprises one or more further layers, and at least one of the one or more further layers comprises a flavorant or a sensate.

In an exemplary embodiment, the aerosolizable material of the wound structure comprises an amorphous solid.

A second aspect of the present disclosure provides a system for heating aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising: the consumable of the first aspect of the present disclosure; and apparatus for heating the aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material, the apparatus comprising a heating zone for receiving the consumable, and a device for causing heating of the aerosolizable material when the consumable is in the heating zone.

In an exemplary embodiment, the device comprises a magnetic field generator for generating a varying magnetic field for penetrating the heating zone when the consumable is in the heating zone.

In an exemplary embodiment, the device for causing heating of the aerosolizable material when the consumable is in the heating zone is configured for heating different sections of the heating zone independently of each other.

A third aspect of the present disclosure provides a method of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, the method comprising: winding a structure comprising aerosolizable material.

In an exemplary embodiment, the aerosolizable material comprises tobacco. In an exemplary embodiment, the aerosolizable material is reconstituted aerosolizable material. In an exemplary embodiment, the aerosolizable material comprises an amorphous solid.

In an exemplary embodiment, the structure comprising aerosolizable material comprises a carrier, and the aerosolizable material is on a surface of the carrier or impregnated in the carrier. In an exemplary embodiment, the structure comprising aerosolizable material consists of the aerosolizable material. For example, the aerosolizable material may be cast or otherwise shaped.

In an exemplary embodiment, the winding comprises helically winding the structure comprising aerosolizable material.

In an exemplary embodiment, the winding comprises winding the structure comprising aerosolizable material around a mandrel.

In an exemplary embodiment, the method comprises applying the aerosolizable material to a material using the mandrel to form the structure.

In an exemplary embodiment, the method comprises winding a material while drawing the material from a supply, and applying the aerosolizable material to the material downstream of the supply.

In an exemplary embodiment, the material is porous to the aerosolizable material.

In an exemplary embodiment, the method comprises drying the aerosolizable material during or after the winding of the structure comprising aerosolizable material.

In an exemplary embodiment, the wound structure forms a layer of the hollow tube, and the method comprises winding one or more further layers. In an exemplary embodiment, the method comprises winding one or more further layers around the structure comprising aerosolizable material. In an exemplary embodiment, the method comprises winding the structure comprising aerosolizable material around one or more layers.

In an exemplary embodiment, the method comprises helically winding the one or more further layers.

In an exemplary embodiment, the method comprises winding the structure comprising aerosolizable material around a mandrel, and winding the one or more layers around the mandrel.

In an exemplary embodiment, at least one of the one or more layers comprises heating material that is heatable by penetration with a varying magnetic field.

In an exemplary embodiment, the winding the structure comprising aerosolizable material comprises winding the structure comprising aerosolizable material to form an innermost surface of the hollow tube.

In an exemplary embodiment, the structure comprising aerosolizable material consists of the aerosolizable material, or comprises a carrier with the aerosolizable material on a surface of the carrier or impregnated in the carrier.

In an exemplary embodiment, the aerosolizable material of the structure comprises an amorphous solid.

A further aspect of the present disclosure may provide the use of the consumable of the first aspect of the present disclosure in the generation of an inhalable aerosol.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a schematic cross-sectional side view of an example of a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material;

FIG. 2 shows a schematic cross-sectional end view of the consumable of FIG. 1 taken along the line II-II in FIG. 1;

FIG. 3 shows a schematic cross-sectional side view of an example of another consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material;

FIG. 4 shows a schematic cross-sectional end view of the consumable of FIG. 3 taken along the line Iv-Iv in FIG. 3;

FIG. 5 shows a schematic cross-sectional side view of an example of a system comprising a consumable and apparatus for heating aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material;

FIG. 6 shows a flow diagram showing an example of a method of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material; and

FIG. 7 shows a flow diagram showing an example of another method of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material.

DETAILED DESCRIPTION

As used herein, the term “aerosolizable material” includes materials that provide volatilized components upon heating, typically in the form of vapor or an aerosol. “Aerosolizable material” may be a non-tobacco-containing material or a tobacco-containing material. “Aerosolizable material” may, for example, include one or more of tobacco per se, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco or tobacco substitutes. The aerosolizable material can be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, gelled sheet, powder, or agglomerates, or the like. “Aerosolizable material” also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. “Aerosolizable material” may comprise one or more humectants, such as glycerol or propylene glycol.

In some embodiments, the aerosolizable material comprises an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous), or as a “dried gel”. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some cases, the aerosolizable material comprises from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid. In some cases, the aerosolizable material consists of amorphous solid.

The amorphous solid may be formed as a sheet. It may be incorporated into the consumable in sheet form. In some cases, the aerosolizable material may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g. tobacco). In some other cases, the aerosolizable material may be formed as a sheet and then shredded and incorporated into the consumable. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the consumable.

In some embodiments, the amorphous solid takes the form of a foam, such as an open celled foam.

“Aerosolizable material” also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. “Aerosolizable material” may comprise one or more humectants, such as glycerol or propylene glycol.

In some cases, the amorphous solid may comprise 1-60 wt % of a gelling agent wherein these weights are calculated on a dry weight basis.

Suitably, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, 30 wt % or 27 wt % of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50 wt %, 5-40 wt %, 10-30 wt % or 15-27 wt % of a gelling agent.

In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from 10-30 wt % of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.

In some embodiments the amorphous solid may include gelling agent comprising carrageenan.

Suitably, the amorphous solid may comprise from about 5 wt %, 10 wt %, 15 wt %, or 20 wt % to about 80 wt %, 70 wt %, 60 wt %, 55 wt %, 50 wt %, 45 wt % 40 wt %, or 35 wt % of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise 10-60 wt %, 15-50 wt % or 20-40 wt % of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of or consists of glycerol. The inventors have established that if the content of the plasticizer is too high, the amorphous solid may absorb water resulting in a material that does not create an appropriate consumption experience in use. The inventors have established that if the plasticizer content is too low, the amorphous solid may be brittle and easily broken. The plasticizer content specified herein provides an amorphous solid flexibility which allows the amorphous solid sheet to be wound onto a bobbin, which is useful in manufacture of aerosol generating articles.

In some cases, the amorphous solid may comprise a flavor. Suitably, the amorphous solid may comprise up to about 60 wt %, 50 wt %, 40 wt %, 30 wt %, 20 wt %, 10 wt % or 5 wt % of a flavor. In some cases, the amorphous solid may comprise at least about 0.1 wt %, 0.5 wt %, 1 wt %, 2 wt %, 5 wt % 10 wt %, 20 wt % or 30 wt % of a flavor (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.1-60 wt %, 1-60 wt %, 5-60 wt %, 10-60 wt %, 20-50 wt % or 30-40 wt % of a flavor. In some cases, the flavor (if present) comprises, consists essentially of or consists of menthol. In some cases, the amorphous solid does not comprise a flavor.

In some cases, the amorphous solid comprises an active substance. For example, in some cases, the amorphous solid comprises a tobacco material and/or nicotine. For example, the amorphous solid may comprise powdered tobacco and/or nicotine and/or a tobacco extract. In some cases, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) of active substance. In some cases, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) of a tobacco material and/or nicotine.

In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60 wt % (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 55 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise 5-60 wt %, 10-55 wt % or 25-55 wt % of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises 1 wt % 1.5 wt %, 2 wt % or 2.5 wt % to about 6 wt %, 5 wt %, 4.5 wt % or 4 wt % (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract.

In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise from about 1 wt %, 2 wt %, 3 wt % or 4 wt % to about 20 wt %, 15 wt %, 10 wt % or 5 wt % (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-20 wt % or 2-5 wt % of nicotine.

In some cases, the total content of active substance and/or flavor may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and/or flavor may be less than about 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight basis).

In some cases, the total content of tobacco material, nicotine and flavor may be at least about 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of tobacco material, nicotine and flavor may be less than about 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight basis).

In some cases, the amorphous solid comprises from about 1 wt % to about 15 wt % water, or from about 5 wt % to about 15 wt % calculated on a wet weight basis. Suitably, the water content of the amorphous solid may be from about 5 wt %, 7 wt % or 9 wt % to about 15 wt %, 13 wt % or 11 wt % (WWB), most suitably about 10 wt %.

In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15 wt %, 12 wt % or 10 wt % of water calculated on a wet weight basis (WWB). In some cases, the hydrogel may comprise at least about 2 wt % or at least about 5 wt % of water (WWB).

The amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at 0.1-50 wt %. However, the inventors have established that the inclusion of a solvent in which the flavor is soluble may reduce the gel stability and the flavor may crystallize out of the gel. As such, in some cases, the gel does not include a solvent in which the flavor is soluble.

In some embodiments, the amorphous solid comprises less than 60 wt % of a filler, such as from 1 wt % to 60 wt %, or 5 wt % to 50 wt %, or 5 wt % to 30 wt %, or 10 wt % to 20 wt %.

In other embodiments, the amorphous solid comprises less than 20 wt %, suitably less than 10 wt % or less than 5 wt % of a filler. In some cases, the amorphous solid comprises less than 1 wt % of a filler, and in some cases, comprises no filler.

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular cases, the amorphous solid comprises no calcium carbonate such as chalk.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler in an amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the amorphous solid is provided as a sheet, such as when an amorphous solid sheet circumscribes a rod of aerosolizable material.

In some embodiments, the amorphous solid does not comprise tobacco fibers.

In particular embodiments, the amorphous solid does not comprise fibrous material.

In some embodiments, the aerosolizable material does not comprise tobacco fibers. In particular embodiments, the aerosolizable material does not comprise fibrous material.

In some embodiments, the aerosol generating substrate does not comprise tobacco fibers. In particular embodiments, the aerosol generating substrate does not comprise fibrous material.

In some embodiments, the consumable does not comprise tobacco fibers. In particular embodiments, the consumable does not comprise fibrous material.

In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, an aerosol generating agent, a tobacco material and/or a nicotine source, water, and optionally a flavor.

A method of making an aerosolizable material may comprise (a) forming a slurry comprising components of the amorphous solid or precursors thereof, (b) forming a layer of the slurry, and (c) setting the slurry to form a gel and (d) drying to form an amorphous solid.

The step (b) of forming a layer of the slurry may comprise spraying, casting or extruding the slurry, for example. In some cases, the layer is formed by electro-spraying the slurry. In some cases, the layer is formed by casting the slurry.

In some cases, the slurry is applied to a carrier.

In some cases, the steps (b) and/or (c) and/or (d) may, at least partially, occur simultaneously (for example, during electro-spraying). In some cases, these steps may occur sequentially.

The step (c) of setting the gel may comprise the addition of a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.

The total amount of the setting agent, such as a calcium source, may be 0.5-5 wt % (calculated on a dry weight basis). The inventors have found that the addition of too little setting agent may result in an amorphous solid which does not stabilize the amorphous solid components and results in these components dropping out of the amorphous solid. The inventors have found that the addition of too much setting agent results in an amorphous solid that is very tacky and consequently has poor handleability.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic (M) and α-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. The inventors have determined that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor pay comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

The drying step may cause the cast material thickness to reduce by at least 80%, suitably 85% or 87%. For instance, the slurry may be cast at a thickness of 2 mm, and the resulting dried amorphous solid material may have a thickness of 0.2 mm.

In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

In some cases, the slurry solvent may consist essentially of or consist of water. In some cases, the slurry may comprise from about 50 wt %, 60 wt %, 70 wt %, 80 wt % or 90 wt % of solvent (WWB).

In cases where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the amorphous solid. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.

In some examples, the slurry has a viscosity of from about 10 to about 20 Pa·s at 46.5° C., such as from about 14 to about 16 Pa·s at 46.5° C.

The aerosolizable material comprising the amorphous solid may have any suitable area density, such as from 30 g/m² to 120 g/m². In some embodiments, aerosolizable material may have an area density of from about 30 to 70 g/m², or about 40 to 60 g/m². In some embodiments, the amorphous solid may have an area density of from about 80 to 120 g/m², or from about 70 to 110 g/m², or particularly from about 90 to 110 g/m². Such area densities may be particularly suitable where the aerosol-generating material is included in a consumable or system in sheet form, or as a shredded sheet (described further hereinbelow).

In some examples, the amorphous solid in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the amorphous solid does not comprise a filler, the amorphous solid may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosolizable material is formed as a sheet and then shredded and incorporated into a consumable. In some examples, such as where the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosolizable material is included in a consumable or system as a rolled sheet, suitably in the form of a tube

In one particular case, the carrier may be a paper-backed foil; the paper layer abuts the amorphous solid layer and the properties discussed in the previous paragraphs are afforded by this abutment. The foil backing is substantially impermeable, providing control of the aerosol flow path. A metal foil backing may also serve to conduct heat to the amorphous solid.

In another case, the foil layer of the paper-backed foil abuts the amorphous solid. The foil is substantially impermeable, thereby preventing water provided in the amorphous solid to be absorbed into the paper which could weaken its structural integrity.

In some cases, the carrier is formed from or comprises metal foil, such as aluminum foil. A metallic carrier may allow for better conduction of thermal energy to the amorphous solid. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, such as from about 1 μm to about 10 μm, suitably about 5 μm.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, and psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine.

In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

Cannabinoids are a class of natural or synthetic chemical compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in cells that repress neurotransmitter release in the brain. Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids), or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, and are divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the botanical is selected from rooibos and fennel.

As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers.

They may include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

The flavor may suitably comprise one or more mint-flavors suitably a mint oil from any species of the genus Mentha. The flavor may suitably comprise, consist essentially of or consist of menthol.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint.

In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry.

In some embodiments, the flavor comprises eugenol.

In some embodiments, the flavor comprises flavor components extracted from tobacco.

In some embodiments, the flavor comprises flavor components extracted from cannabis.

In some embodiments, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3.

As used herein, the term “aerosol generating agent” refers to an agent that promotes the generation of an aerosol. An aerosol generating agent may promote the generation of an aerosol by promoting an initial vaporization and/or the condensation of a gas to an inhalable solid and/or liquid aerosol.

Suitable aerosol generating agents include, but are not limited to: a polyol such as erythritol, sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol generating agent may suitably have a composition that does not dissolve menthol. The aerosol generating agent may suitably comprise, consist essentially of or consist of glycerol.

As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives therefore. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be tobacco particle ‘fines’ or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibers, and may be formed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.

In some embodiments, the amorphous solid comprises menthol.

Particular embodiments comprising a menthol-containing amorphous solid may be particularly suitable for including in a consumable or system as a shredded sheet. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of from about 20 wt % to about 40 wt %, or about 25 wt % to 35 wt %; menthol in an amount of from about 35 wt % to about 60 wt %, or from about 40 wt % to 55 wt %; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10 wt % to about 30 wt %, or from about 15 wt % to about 25 wt % (DWB).

In one embodiment, the amorphous solid comprises about 32-33 wt % of an alginate/pectin gelling agent blend; about 47-48 wt % menthol flavorant; and about 19-20 wt % glycerol aerosol generating agent (DWB).

As noted above, the amorphous solid of these embodiments may be included in a consumable or system as a shredded sheet. The shredded sheet may be provided in the consumable or system blended with cut tobacco. Alternatively, the amorphous solid may be provided as a non-shredded sheet. Suitably, the shredded or non-shredded sheet has a thickness of from about 0.015 mm to about 1 mm, preferably from about 0.02 mm to about 0.07 mm.

Particular embodiments of the menthol-containing amorphous solid may be particularly suitable for including in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g. tobacco). In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of from about 5 wt % to about 40 wt %, or about 10 wt % to 30 wt %; menthol in an amount of from about 10 wt % to about 50 wt %, or from about 15 wt % to 40 wt %; aerosol generating agent (preferably comprising glycerol) in an amount of from about 5 wt % to about 40 wt %, or from about 10 wt % to about 35 wt %; and optionally filler in an amount of up to 60 wt %—for example, in an amount of from 5 wt % to 20 wt %, or from about 40 wt % to 60 wt % (DWB).

In one of these embodiments, the amorphous solid comprises about 11 wt % of an alginate/pectin gelling agent blend, about 56 wt % woodpulp filler, about 18% menthol flavorant and about 15 wt % glycerol (DWB).

In another of these embodiments, the amorphous solid comprises about 22 wt % of an alginate/pectin gelling agent blend, about 12 wt % woodpulp filler, about 36% menthol flavorant and about 30 wt % glycerol (DWB).

As noted above, the amorphous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is provided on a carrier comprising paper. In one embodiment, the sheet is provided on a carrier comprising metal foil, suitably aluminum metal foil. In this embodiment, the amorphous solid may abut the metal foil.

In one embodiment, the sheet forms part of a laminate material with a layer (preferably comprising paper) attached to a top and bottom surface of the sheet. Suitably, the sheet of amorphous solid has a thickness of from about 0.015 mm to about 1 mm.

In some embodiments, the amorphous solid comprises a flavorant which does not comprise menthol. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5 to about 40 wt %, or from about 10 wt % to about 35 wt %, or from about 20 wt % to about 35 wt %; flavorant in an amount of from about 0.1 wt % to about 40 wt %, of from about 1 wt % to about 30 wt %, or from about 1 wt % to about 20 wt %, or from about 5 wt % to about 20 wt %; aerosol generating agent (preferably comprising glycerol) in an amount of from 15 wt % to 75 wt %, or from about 30 wt % to about 70 wt %, or from about 50 wt % to about 65 wt %; and optionally filler (suitably woodpulp) in an amount of less than about 60 wt %, or about 20 wt %, or about 10 wt %, or about 5 wt % (preferably the amorphous solid does not comprise filler) (DWB).

In one of these embodiments, the amorphous solid comprises about 27 wt % alginate gelling agent, about 14 wt % flavorant and about 57 wt % glycerol aerosol generating agent (DWB).

In another of these embodiments, the amorphous solid comprises about 29 wt % alginate gelling agent, about 9 wt % flavorant and about 60 wt % glycerol (DWB).

The amorphous solid of these embodiments may be included in a consumable or system as a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g. tobacco). Alternatively, the amorphous solid of these embodiments may be included in a consumable or system as a layer portion disposed on a carrier.

In some embodiments, the amorphous solid comprises tobacco extract. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5 wt % to about 40 wt %, or about 10 wt % to 30 wt %, or about 15 wt % to about 25 wt %; tobacco extract in an amount of from about 30 wt % to about 60 wt %, or from about 40 wt % to 55 wt %, or from about 45 wt % to about 50 wt %; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10 wt % to about 50 wt %, or from about 20 wt % to about 40 wt %, or from about 25 wt % to about 35 wt % (DWB).

In one embodiment, the amorphous solid comprises about 20 wt % alginate gelling agent, about 48 wt % Virginia tobacco extract and about 32 wt % glycerol (DWB).

The amorphous solid of these embodiments may have any suitable water content. For example, the amorphous solid may have a water content of from about 5 wt % to about 15 wt %, or from about 7 wt % to about 13 wt %, or about 10 wt %.

The amorphous solid of these embodiments may be included in a consumable or system as a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g. tobacco). Alternatively, the amorphous solid of these embodiments may be included in a consumable or system as a layer portion disposed on a carrier. Suitably, in any of these embodiments, the amorphous solid has a thickness of from about 50 μm to about 200 μm, or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, suitably about 77 μm.

The slurry for forming this amorphous solid may also form part of the invention. In some cases, the slurry may have an elastic modulus of from about 5 to 1200 Pa (also referred to as storage modulus); in some cases, the slurry may have a viscous modulus of about 5 to 600 Pa (also referred to as loss modulus).

All percentages by weight described herein (denoted wt %) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.

As used herein, the term “sheet” denotes an element having a width and length substantially greater than a thickness thereof. The sheet may be a strip, for example.

As used herein, the term “heating material” or “heater material” refers to material that is heatable by penetration with a varying magnetic field.

Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating. An object that is capable of being inductively heated is known as a susceptor.

It has been found that, when the susceptor is in the form of a closed electrical circuit, magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.

When an object is both electrically-conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule and magnetic hysteresis heating.

In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower.

Referring to FIGS. 1 and 2, there are shown schematic cross-sectional side and end views of an example of a consumable according to an embodiment of the disclosure. The consumable 1 is for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, such as the apparatus 100 shown in FIG. 5 and described below. The apparatus may be a tobacco heating product (also known in the art as a tobacco heating device or a heat-not-burn device).

The consumable 1 comprises a hollow tube 1 a. The hollow tube 1 a defines a passageway 20 therein. The hollow tube 1 a comprises a wound structure 10 comprising aerosolizable material. In this embodiment, the wound structure 10 is a helically wound structure comprising aerosolizable material. However, in other embodiments, the wound structure may be non-helically wound. For example, the structure comprising aerosolizable material may be non-helically spirally wound.

In some embodiments, the aerosolizable material of the structure 10 comprises tobacco. In some embodiments, the aerosolizable material comprises reconstituted aerosolizable material, such as reconstituted tobacco. In some embodiments, the aerosolizable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card. In other embodiments, the aerosolizable material may be in any of the other forms discussed herein. The structure comprising aerosolizable material may comprise a carrier such as paper or card, and the aerosolizable material may be on a surface of the carrier or impregnated in the carrier. For example, the aerosolizable material may comprise tobacco extract. In some embodiments, the structure comprising aerosolizable material consists of the aerosolizable material. For example, the aerosolizable material may be cast or otherwise shaped.

In this embodiment, the wound structure 10 comprising aerosolizable material defines both an innermost surface 1 b of the hollow tube 1 a and an outermost surface 1 c of the hollow tube 1 a. Indeed, in some embodiments, the hollow tube 1 a consists of, or substantially consists of, the wound structure 10 comprising aerosolizable material. In other embodiments, as will be understood from the discussion below, the innermost surface 1 b of the hollow tube 1 a and/or the outermost surface 1 c of the hollow tube 1 a may be defined by a part of the consumable other than the wound structure 10 comprising aerosolizable material. The part may be another layer of the hollow tube 1 a or of the consumable. In some embodiments, the wound structure 10 comprising aerosolizable material defines only part of the innermost surface 1 b of the hollow tube 1 a and/or only part of the outermost surface 1 c of the hollow tube 1 a, as a result of another part of the hollow tube 1 a or consumable defining some or all of the rest of the innermost and/or outermost surface, respectively.

In this embodiment, the structure 10 comprising aerosolizable material is circular. In other embodiments, the wound structure 10 comprising aerosolizable material comprises corrugations, embossing or debossing. Such an arrangement may increase the surface area over which an aerosol is able to form from the aerosolizable material in use.

Referring to FIGS. 3 and 4, there are shown schematic cross-sectional side and end views of an example of another consumable according to an embodiment of the disclosure. The consumable 2 of FIGS. 3 and 4 is for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, such as the apparatus 100 shown in FIG. 5 and described below. The apparatus may be a tobacco heating product (also known in the art as a tobacco heating device or a heat-not-burn device).

The consumable 2 comprises a hollow tube 2 a. The hollow tube 2 a defines a passageway 20 therein. The hollow tube 2 a comprises plural layers 10, 11, 12, 13. In some embodiments, two or some or all of the plural layers 10, 11, 12, 13 are bonded together such that the plural layers form a laminate.

One of the layers is a wound structure 10 comprising aerosolizable material. In this embodiment, the wound structure 10 is a helically wound structure comprising aerosolizable material. However, in other embodiments, the wound structure may be non-helically wound. For example, the structure comprising aerosolizable material may be non-helically spirally wound.

In some embodiments, the aerosolizable material of the structure 10 comprises tobacco. In some embodiments, the aerosolizable material is reconstituted aerosolizable material, such as reconstituted tobacco. In some embodiments, the aerosolizable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card. The structure comprising aerosolizable material may comprise a carrier such as paper or card, and the aerosolizable material may be on a surface of the carrier or impregnated in the carrier. For example, the aerosolizable material may comprise tobacco extract. In some embodiments, the structure comprising aerosolizable material consists of the aerosolizable material. For example, the aerosolizable material may be cast or otherwise shaped.

In this embodiment, the wound structure 10 comprising aerosolizable material defines a surface of the hollow tube 2 a, and more specifically an innermost surface 2 b of the hollow tube 2 a. In other embodiments, the wound structure 10 comprising aerosolizable material defines only part of the innermost surface 2 b hollow tube 2 a, as a result of another part of the hollow tube 2 a or of the consumable defining some or all of the rest of the innermost surface 2 b.

The wound structure 10 comprising aerosolizable material comprises corrugations in this embodiment. In other embodiments, the structure 10 additionally or alternatively comprises embossing or debossing, so as to be embossed or debossed, respectively. As mentioned elsewhere herein, such an arrangement may increase the surface area over which an aerosol is able to form from the aerosolizable material in use. In still other embodiments, the wound structure 10 comprising aerosolizable material is free from corrugations, embossings or debossings.

As noted above, the hollow tube 2 a comprises further layers 11, 12, 13. It is to be noted that not all of these further layers 11, 12, 13 may be present in all embodiments. In this embodiment, each of the further layers 11, 12, 13 is a wound layer, such as a helically wound layer, but in other embodiments one or more of the further layers 11, 12, 13 may be a non-wound layer, such as a cast or extruded layer.

In this embodiment, the consumable 2 comprises heating material that is heatable by penetration with a varying magnetic field. The heating material may be any of those discussed herein. The heating material is heatable to heat the aerosolizable material of the wound structure 10. In this embodiment, the hollow tube 2 a comprises a layer 11 comprising the heating material. More specifically, the layer 11 comprising heating material is radially adjacent and abuts the wound structure 10 comprising aerosolizable material, so that heat energy generated in the heating material in use is able efficiently to pass to the aerosolizable material. In this embodiment, the layer 11 comprising heating material is located radially outwards of the wound structure 10 comprising aerosolizable material, but in other embodiments the layer 11 comprising heating material may be located radially inwards of the wound structure 10 comprising aerosolizable material.

In this embodiment, the layer 11 comprising heating material is a wound layer, such as a helically wound layer, and the layer 11 comprising heating material has been wound around the structure 10 comprising aerosolizable material. In other embodiments, the layer 11 comprising heating material may be non-wound. In some embodiments, the layer 11 comprising heating material comprises a carrier, such as paper, carrying the heating material. In other embodiments, the layer 11 comprising heating material comprises a foil, such as a metal or metal alloy foil, such as aluminum foil. In some embodiments, the layer 11 comprising heating material may be omitted. Indeed, in some embodiments, the consumable 2 may be free from heating material that is heatable by penetration with a varying magnetic field.

In this embodiment, the aerosolizable material of the wound structure 10 adheres the wound structure 10 to the layer 11 comprising heating material. In other embodiments, this may not be the case and/or the aerosolizable material of the wound structure 10 may adhere the wound structure 10 to a different layer or part of the hollow tube 2 a. In some embodiments, a separate adhesive may be used to adhere layers to each other.

As noted above, in this embodiment, the structure 10 comprising aerosolizable material comprises corrugations, and in some other embodiments the structure 10 additionally or alternatively comprises embossing or debossing. The hollow tube 2 a of this embodiment comprises one or more aerosol flow paths 17 defined by and between the corrugations, embossing or debossing of the structure 10 comprising aerosolizable material and the layer 11 comprising heating material. The aerosol flow path(s) extend in the axial direction of the hollow tube 2 a and provide a route via which aerosol generated in or from the aerosolizable material is able to leave the hollow tube 2 a. This may be particularly advantageous when the passageway 20 of the consumable 2 is filled by a heating element of an apparatus with which the consumable 2 is useable. In other embodiments, such as those in which the hollow tube 2 a is free from heating material, the one or more aerosol flow paths may be defined by and between the corrugations, embossing or debossing of the structure 10 comprising aerosolizable material and another layer or part of the hollow tube 2 a, such as the other layer 12 or the barrier layer 13 described below.

In this embodiment, the hollow tube 2 a comprises a barrier layer 13 that defines a surface of the hollow tube 2 a. In this embodiment, the surface is an outermost surface 2 c of the hollow tube 2 a. Therefore, the barrier layer 13 is located radially outwards of the wound structure 10 of aerosolizable material. Moreover, the layer 11 comprising heating material is located between the barrier layer 13 and the structure 10 comprising aerosolizable material, and abuts the structure 10 comprising aerosolizable material. In some embodiments, the barrier layer 13 defines only part of the outermost surface 2 c of the hollow tube 2 a, as a result of another part of the hollow tube 2 a or consumable defining some or all of the rest of the outermost surface 2 c. In some embodiments, the barrier layer 13 is a wound layer, such as a helically wound layer, but in other embodiments the barrier layer 13 may be a non-wound layer.

The barrier layer 13 may, for example, comprise one or more materials selected from the group consisting of: paper, card, paperboard, cardboard, reconstituted tobacco, a plastics material, and heating material. The barrier layer 13 may help to provide the hollow tube 2 a with rigidity. In some embodiments, such as those in which the barrier layer 13 abuts or is adjacent to the structure 10 comprising aerosolizable material, the barrier layer 13 is impermeable to aerosol generated in or from the structure 10 in use. This may help to prevent or discourage the generated aerosol from contacting the apparatus, or depositing in the apparatus, with which the consumable 2 is usable. It may also help to channel the aerosol generated in or from the aerosolizable material along and out of the hollow tube 2 a. In some embodiments, the barrier layer 13 is omitted.

The consumable 2 of this embodiment comprises another layer 12, which is radially adjacent and abuts the layer 11 comprising heating material, so that heat energy generated in the heating material in use is able efficiently to pass to the other layer 12. In this embodiment, the layer 11 comprising heating material is located radially inwards of the other layer 12, but in other embodiments the layer 11 comprising heating material may be located radially outwards of the other layer 12. The other layer 12 is thus located between the barrier layer 13 and the layer 11 comprising heating material. The other layer 12 also abuts the barrier layer 13, in this embodiment.

In some embodiments, the other layer 12 comprises aerosolizable material. In some such embodiments, the hollow tube 2 a thus comprises a layer 11 comprising heating material that is located between the wound structure 10 comprising aerosolizable material and the other layer 12 comprising aerosolizable material. The aerosolizable material of the other layer 12 may adhere the other layer 12 to the barrier layer 13 and/or to the layer 11 comprising heating material. In some embodiments, the aerosolizable material of the other layer 12 comprises tobacco. In some embodiments, the aerosolizable material is reconstituted aerosolizable material, such as reconstituted tobacco. In some embodiments, the aerosolizable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card. In some embodiments, additionally or alternatively to aerosolizable material, the other layer 12 may comprise a flavorant or a sensate, for example. In some embodiments, the other layer 12 is omitted.

In some embodiments, the other layer 12 is a wound layer, such as a helically wound layer, but in other embodiments the other layer 12 may be a non-wound layer. In some embodiments, the other layer 12 has been wound around the layer 11 comprising heating material or whatever other layer is radially inwards of the other layer 12. Similarly, in some embodiments, the barrier layer 13 has been wound around the other layer 12.

In some embodiments, the aerosolizable material of the other layer 12 has a different form or chemical composition to the aerosolizable material of the structure 10. For example, in some embodiments, the difference in form may comprise a difference in mean particle size of the aerosolizable material. Typically, particles of aerosolizable material having a smaller mean particle size are heatable more quickly, for example to volatilize at least one component of the aerosolizable material, by a given heat source than are particles of the aerosolizable material having a greater mean particle size.

In some embodiments, the difference in form may comprise the aerosolizable material of one of the structure 10 and layer 12 being in the form of reconstituted aerosolizable material (such as reconstituted tobacco) and the aerosolizable material of the other of the structure 10 and layer 12 comprising an amorphous solid.

In some embodiments, the difference in chemical composition may comprise a difference in the ingredient or ingredients of the aerosolizable material, such as a difference in chemical compositions of respective amorphous solids. In some embodiments, the difference in chemical composition may comprise a difference in the type or density of aerosol forming agent, such as glycerol, in the aerosolizable material. In some embodiments, the difference in chemical composition may comprise a difference in quantities by weight of a smoke modifying agent, such as a flavorant as a percentage of a total weight of aerosolizable material.

In some embodiments, the layer 12 (when provided) and/or the wound structure 10 comprising aerosolizable material may comprise plural, spaced apart discrete regions of aerosolizable material. In use, such discrete regions of aerosolizable material may be heatable independently by respective heaters of an apparatus with which the consumable 2 is usable.

Accordingly, as noted above, in some embodiments the plurality of layers 10, 11, 12, 13 of the hollow consumable 2 a may be wound layers, wherein outward ones of the layers 11, 12, 13 have been wound around inward ones of the layers 10, 11, 12. Example methods for manufacturing such hollow tubes 2 a are discussed below.

In some embodiments, an order of the layers 10, 11, 12, 13 of the hollow consumable 2 a may be other than that shown in FIGS. 3 and 4. For example, in some embodiments, the consumable may have a wound structure comprising aerosolizable material that forms at least part of an outermost surface of the hollow tube, and a layer comprising heating material that is located radially inwards of the structure comprising aerosolizable material.

In some embodiments, the hollow tube 2 a may comprise at least one additional layer, which may or may not be a wound layer, such as a helically wound layer.

In each of the embodiments of FIGS. 1 to 4, the hollow tube 1 a, 2 a has circular inner and outer cross-sectional shapes. In other embodiments, one or each of the inner and outer cross-sectional shapes of the hollow tube may be non-circular, such as elliptical, polygonal, rectangular, square, triangular, or star-shaped.

In each of the embodiments discussed above, the hollow tube 1 a, 2 a extends along an axis A-A. The axis A-A is a central axis that extends along the passageway 20, but in other embodiments the configuration of the consumable 1, 2 may be such that the axis A-A is offset from the passageway 20. In the illustrated embodiments, the consumable 1, 2 is elongate in the direction of the axis A-A, but in other embodiments a width or diameter of the consumable 1, 2 may be greater than or equal to a dimension of the consumable 1, 2 in the direction of the axis A-A, so that the consumable 1, 2 is not elongate. Moreover, in the illustrated embodiments, the hollow tube 1 a, 2 a of the consumable 1, 2 is elongate in the direction of the axis A-A, but in other embodiments a width or diameter of the hollow tube 1 a, 2 a may be greater than or equal to a dimension of the hollow tube 1 a, 2 a in the direction of the axis A-A, so that the hollow tube 1 a, 2 a is not itself elongate.

In each of the embodiments of FIGS. 1 to 4, the passageway 20 opens at an axial end 15 of the hollow tube 1 a, 2 a, and indeed the consumable 1, 2. In some embodiments, such as some of those in which the consumable is free from heating material, a heating element of the apparatus may be insertable into the passageway 20 in use, as will be discussed in more detail below. In each of the embodiments of FIGS. 1 to 4, the passageway 20 extends fully through the hollow tube 1 a, 2 a from one axial end 15 of the hollow tube 1 a, 2 a to an opposite axial end 16 of the hollow tube 1 a, 2 a. Moreover, in each of these embodiments, the passageway 20 extends fully through the consumable 1, 2 from a first axial end 15 of the consumable 1, 2 to an opposite second axial end 16 of the consumable 1, 2. However, in some embodiments, the passageway 20 may extend only partially along a length or axial dimension of the consumable 1, 2, such as for a majority of the length or axial dimension of the consumable 1, 2 or for a minority of a length or axial dimension of the consumable 1, 2.

In some embodiments, the hollow tube 1 a, 2 a extends for a full length or axial dimension of the consumable 1, 2. In other embodiments, the consumable 1, 2 may comprise one or more elements (not shown) at one or each axial end of the hollow tube 1 a, 2 a, so that the hollow tube 1 a, 2 a extends for only part of the length or axial dimension of the consumable 1, 2.

In some embodiments, the consumable 1, 2 comprises a porous body (not shown). The porous body may be for filtering aerosol or vapor released from the aerosolizable material in use. Alternatively, or additionally, the porous body may be for controlling the pressure drop over a length or axial dimension of the consumable 1, 2. The porous body could be of any type used in the tobacco industry. For example, the porous body may be made of cellulose acetate. In some embodiments, the porous body is substantially cylindrical with a substantially circular cross section and a longitudinal axis. In other embodiments, the filter may have a different cross section or not be elongate.

In some embodiments, the porous body abuts an axial end 15, 16 of the hollow tube 1 a, 2 a and is axially aligned with the hollow tube 1 a, 2 a. In other embodiments, the porous body may be spaced from the hollow tube 1 a, 2 a, such as by a gap and/or by one or more further components of the consumable 1, 2. Example further component(s) are an additive or flavor source (such as an additive- or flavor-containing capsule or thread), which may be held by a body of filtration material or between two bodies of filtration material, for example.

The consumable 1, 2 may also comprise a wrap that is wrapped around the hollow tube 1 a, 2 a and the porous body to retain the porous body relative to the hollow tube 1 a, 2 a. The wrap may encircle the hollow tube 1 a, 2 a and the porous body. The wrap may be wrapped around the hollow tube 1 a, 2 a and the porous body so that free ends of the wrap overlap each other. The wrap may form part of, or all of, a circumferential outer surface of the consumable 1, 2. The wrap could be made of any suitable material, such as paper, card, or reconstituted aerosolizable material (e.g. reconstituted tobacco). The wrap may also comprise an adhesive that adheres the overlapped free ends of the wrap to each other. The adhesive helps prevent the overlapped free ends of the wrap from separating. In other embodiments, the adhesive may be omitted or the wrap may take a different from to that described. In other embodiments, the porous body may be retained relative to the hollow tube 1 a, 2 a by a connector other than a wrap, such as an adhesive.

In some embodiments, the consumable 1, 2 has a length or an axial dimension of between 30 millimeters and 150 millimeters, such as between 70 millimeters and 120 millimeters.

In some embodiments, the consumable 1, 2 has an inner dimension (e.g. an inner diameter) in a direction perpendicular to the axial direction of between 2 millimeters and 10 millimeters, such as between 4 millimeters and 8 millimeters.

In some embodiments, the consumable 1, 2 has an outer dimension (e.g. an outer diameter) in a direction perpendicular to the axial direction of between 4 millimeters and 10 millimeters, such as between 4.5 millimeters and 8 millimeters.

In some embodiments, the aerosolizable material, wherever provided in the consumable 1, 2, has a thickness of between 0.05 millimeters and 2 millimeters, such as between 0.05 millimeters and 1 millimeter, or such as between 0.1 millimeters and 1 millimeter, or such as between 0.15 millimeters and 0.5 millimeters. The thickness may be less than or equal to 1 millimeter, such as less than or equal to 0.5 millimeters, or less than or equal to 0.25 millimeters, or less than or equal to 0.2 millimeters, or less than or equal to 0.1 millimeters, or less than or equal to 0.05 millimeters.

As noted herein, the wound structure may comprising aerosolizable material may comprise corrugations, embossing or debossing. In some such embodiments, the corrugations, embossing or debossing define a plurality of troughs or depressions, and aerosolizable material (such as an amorphous solid described herein) is disposed in at least one of the troughs or depressions, such as a plurality of the troughs or depressions.

Example methods of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material will now be described. Any of the following methods may be used in the manufacture of any of the hollow tubes described herein, for example.

FIG. 6 shows a flow diagram showing an example of a method of manufacturing such a hollow tube. The method 600 comprises winding 601 a structure comprising aerosolizable material.

The aerosolizable material may, for example, be any of those discussed herein. In some embodiments, the aerosolizable material comprises tobacco. In some embodiments, the aerosolizable material is reconstituted aerosolizable material, such as reconstituted tobacco. In some embodiments, the aerosolizable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card. The structure comprising aerosolizable material may comprises a carrier such as paper or card, and the aerosolizable material may be on a surface of the carrier or impregnated in the carrier. For example, the aerosolizable material may comprise tobacco extract. In some embodiments, the structure comprising aerosolizable material consists of the aerosolizable material. For example, the aerosolizable material may be cast or otherwise shaped.

In some embodiments, the winding 601 comprises helically winding the structure comprising aerosolizable material. In some embodiments, the winding 601 comprises spirally winding the structure comprising aerosolizable material. In some embodiments, the winding 601 comprises helically-spirally winding the structure comprising aerosolizable material so that the structure adopts a helical spiral form.

The winding 601 may comprise winding the structure comprising aerosolizable material around a mandrel. The mandrel may be made of any suitable material, such as a metal, metal alloy, or a plastics material such as polyether ether ketone (PEEK). Alternatively, a mandrel may not be used. For instance, the structure comprising aerosolizable material may be wound using a garniture. In embodiments in which the structure comprising aerosolizable material comprises corrugations or embossings or debossings, a surface of the mandrel may be correspondingly shaped so as to engage with the corrugations, embossings or debossings.

In some embodiments, the winding 601 comprises winding the structure comprising aerosolizable material to form an innermost surface of the hollow tube. In other embodiments, the structure comprising aerosolizable material may be wound around one or more other elements of the hollow tube being manufactured, such as one or more helically-wound layers, so that the structure comprising aerosolizable material does not form an innermost surface of the hollow tube.

In some embodiments, the structure comprising aerosolizable material comprises aerosolizable material on a surface of a carrier, such as paper. In some such embodiments, the method comprises winding the carrier and the aerosolizable material around a mandrel with the carrier in contact with the mandrel and the aerosolizable material outermost, and then winding a layer, such as of paper, onto the aerosolizable material. This forms an arrangement in which the aerosolizable material is sandwiched between the carrier and the layer.

FIG. 7 shows a flow diagram showing an example of another method of manufacturing a hollow tube for use in or as a consumable. The method 700 comprises drawing 701 material from a supply, such as a bobbin or spool. The material may, for example, be paper or card. The method also comprises winding 702 the material while drawing it from the supply. The winding 702 may be helical winding, for example. The winding 702 may comprise winding the material around a mandrel. The mandrel may be made of any of the mandrel materials discussed herein, for example.

In some embodiments, the material drawn from the supply already has aerosolizable material thereon or therein. However, in some alternative embodiments, the method comprises applying 703 aerosolizable material to the material downstream of the supply. The aerosolizable material may be any of those discussed herein. The applying 703 may be performed upstream of the point at which the winding 702 of the material is performed. Alternatively, in embodiments in which the winding 702 comprises winding the material around a mandrel, the applying 703 may be performed using the mandrel. For example, the aerosolizable material may be passed, such as pumped, in fluid form through the mandrel and into contact with the material while the material is on the mandrel. The mandrel may include a first portion around which the material is wound or wrapped, and a second portion downstream of the first portion and including aerosolizable material supply holes thorough which the aerosolizable material passes into contact with the material. The first portion of the mandrel may be free from aerosolizable material supply holes. The material may be porous, or non-porous, to the aerosolizable material. Following the application 703 of the aerosolizable material to the material, the material carrying the aerosolizable material continues to be wrapped around the mandrel.

In some embodiments, the aerosolizable material may be applied to an external surface of the mandrel, or to the material on the mandrel or upstream of the mandrel, without first passing through the mandrel. The aerosolizable material may take the form of a slurry, when so applied.

The method may further comprise drying 704 the aerosolizable material during, or after, the winding 702 of the structure.

In some embodiments, the structure comprising aerosolizable material consists of the aerosolizable material. The aerosolizable material may be cast or otherwise shaped. For example, the aerosolizable material may be cast as a block, and then rolled or otherwise pressed into a thinner form, such as a layer or sheet.

The structure comprising aerosolizable material may, for example, include corrugations or embossings or debossings when in the supply, or the structure may be passed through a station at which the corrugations or embossings or debossings are made in the structure after it has been drawn from the supply.

The method may also comprise winding 705 one or more layers, for example helically. The one or more layers may be wound around the mandrel, when used. The one or more layers may be wound around the structure comprising aerosolizable material. Alternatively, the structure comprising aerosolizable material may be wound around the one or more layers. In some embodiments, the structure comprising aerosolizable material may be wound around one or more layers, and then one or more further layers may be wound around the structure comprising aerosolizable material.

At least one of the layers may comprise heating material that is heatable by penetration with a varying magnetic field. The heating material may be any one of those discussed herein, for example. At least one of the layers may comprise a flavorant or sensate. At least one of the layers may comprise aerosolizable material. The aerosolizable material may be any one of those discussed herein, for example.

Accordingly, when a mandrel is used, in some embodiments the mandrel may be considered to have different zones: one in which aerosolizable material is applied to the material to form the structure comprising aerosolizable material, one in which the structure is wound, one in which the aerosolizable material is dried or allowed to dry, and optionally one or more zones in which the one or more layers may be wound around the structure comprising aerosolizable material.

In some embodiments, different materials or layers may be wrapped around the mandrel from diametrically opposite sides of the mandrel. These different materials may be wrapped around the mandrel at a certain common region in the length direction of the mandrel. Each of the materials or layers may be of any type discussed herein, for example.

In some embodiments, in order to reduce sticking of the aerosolizable material to the mandrel, the aerosolizable material may be coated with, or comprise, a release agent. Alternatively, or additionally, the mandrel may be coated with a release agent, or may be heated or tapered or include a gas blower or ultrasonic vibrator to discourage sticking of the aerosolizable material to the mandrel, or to encourage release of the aerosolizable material from the mandrel if sticking were to occur. The gas blower may comprise one or more apertures in the surface of the mandrel on which the aerosolizable material or material is wound in use, and a source of gas, such as air, for supplying gas to the one or more apertures in the surface of the mandrel. In some embodiments, the mandrel could be made of porous material, and the gas could be supplied from the gas source to a surface of the mandrel via pores in the mandrel.

The method may result in the formation of a continuous hollow tube. The continuous hollow tube may be drawn from the mandrel while or after the winding takes place. The method may then comprise separating 706, such as by cutting, the continuous hollow tube to form discrete hollow tubes that can be incorporated into, or form, a consumable for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material.

In manufacturing the hollow tube 2 a shown in FIGS. 3 and 4, the winding 702 may comprise winding the material to form an innermost surface of the hollow tube, and the winding 705 of layers may comprise winding a layer comprising heating material around the structure comprising aerosolizable material, winding another layer comprising aerosolizable material around the layer comprising heating material, and winding a barrier layer around the other layer comprising aerosolizable material.

In another embodiment, the method may comprise providing aerosolizable material, such as comprising an amorphous solid, on a carrier, such as paper so as to provide the structure comprising aerosolizable material. The aerosolizable material may be coated, such as cast, band-cast, sprayed or electro-sprayed, on the carrier. The structure may be stored as a supply, on a bobbin for example. The structure may be drawn, from the supply for example, and wound, either around a mandrel or not, so that free ends of the structure are circumferentially adjacent or abutting, but not overlapping, thereby to create a tube or a near-tubular form with a substantially uniform diameter. The tube may thus have a seamless join between the free ends. The aerosolizable material may face an inner hollow space of the tube or near-tubular form. A layer, such as of paper, may be wound around the outside of the tube or near-tubular form, and optionally adhered thereto, so as to help maintain the shape of the tube or near-tubular form. This layer similarly may have free ends that are adjacent or abut, but do not overlap. The adhesive, when used, may be band casted onto the structure. As the free ends of the structure do not overlap, such a method is usable to form a hollow tube that is purely, or at least closer to, circular or regular in cross-section, than a comparative hollow tube that includes overlapping free ends of material. This means that more uniform heating of the aerosolizable material may be possible in use, as all regions of the aerosolizable material may be more easily equally spaced from a heating element that heats the aerosolizable material in use. However, in other embodiments, the free ends of the combination may overlap.

In some of the embodiments in which the aerosolizable material is carried by a carrier, a surface of the carrier that abuts the aerosolizable material may be porous. For example, in some cases, the carrier comprises paper. In some embodiments, the carrier comprises or consists of a tobacco material, such as a sheet of reconstituted tobacco, which may be porous. The inventors have found that a porous carrier such as paper is particularly suitable for some embodiments of the present disclosure; the porous layer abuts the aerosolizable material and forms a strong bond. The amorphous solid of the aerosolizable material of some embodiments is formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed partially impregnates the porous carrier (e.g. paper) so that when the gel sets and forms cross-links, the carrier is partially bound into the gel. This provides a strong binding between the gel and the carrier (and between the dried gel and the carrier). The porous layer (e.g. paper) may also be used to carry flavors. In some cases, the porous layer may comprise paper, suitably having a porosity of 0-300 Coresta Units (CU), suitably 5-100 CU or 25-75 CU.

Additionally, surface roughness may contribute to the strength of bond between the aerosolizable material and the carrier. The inventors have found that the paper roughness (for the surface abutting the aerosolizable material) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the “Bekk smoothness”.)

In some embodiments, the consumable 1, 2 is suitable for insertion into a heating zone of an apparatus, such as the heating zone 110 of the apparatus 100 shown in FIG. 5, wherein the apparatus has a device for causing heating of the aerosolizable material of the consumable 1, 2 when the consumable 1, 2 is in the heating zone. Once in the heating zone 110, the device of the apparatus causes heating of the aerosolizable material to volatilize at least one component of the aerosolizable material.

In some embodiments, the device is configured to apply heat energy to the consumable 1, 2, and specifically to the aerosolizable material thereof. In some such embodiments, the device comprises a resistive heater that is heated by electrically connecting the resistive heater to a supply of electricity, and heat energy passes from the resistive heater to the consumable 1, 2.

In some other embodiments, the device may comprise a magnetic field generator for generating a varying magnetic field for penetrating the heating zone when the consumable 1, 2 is in the heating zone 110, and the consumable 1, 2 comprises heating material that is heatable by penetration with the varying magnetic field to thereby heat the aerosolizable material. Accordingly, in such embodiments, the device is configured to cause electromagnetic energy to be applied to the heating material of the consumable 1, 2 to create heat in the heating material, and then heat energy is applied from the heating material to the aerosolizable material. In some embodiments, the consumable 1, 2 may comprise heating material that is partially or fully embedded in the aerosolizable material.

In still further embodiments, the apparatus 100 has a heatable element comprising heating material, wherein the heatable element is in thermal contact with the heating zone, and wherein the magnetic field generator is for generating a varying magnetic field for penetrating the heatable element of the apparatus, so as to cause heating of the heatable element and thus the heating zone. Heat energy is thus applied to any consumable present in the heating zone.

In any event, the volatilized component(s) of the aerosolizable material pass from the aerosolizable material and out of the consumable 1, 2, such as by a user drawing on the consumable 1, 2 or a mouthpiece (when provided) of the apparatus.

Referring to FIG. 5, there is shown a schematic cross-sectional side view of an example of a system comprising a consumable and apparatus for heating aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material, according to an embodiment of the disclosure.

The system 1000 comprises the consumable 1 of FIGS. 1 and 2 and apparatus 100 for heating the aerosolizable material of the consumable 1 to volatilize at least one component of the aerosolizable material. In other embodiments, the consumable may be replaced by any of the other consumables described herein, such as the consumable 2 shown in FIGS. 3 and 4. In this embodiment, the apparatus 100 is a tobacco heating product (also known in the art as a tobacco heating device or a heat-not-burn device).

The apparatus comprises a heating zone 110 for receiving the consumable 1, 2, and a device 112 for causing heating of the aerosolizable material when the consumable 1, 2 is in the heating zone 110.

The apparatus 100 may define at least one air inlet (not shown) that fluidly connects the heating zone 110 with the exterior of the apparatus 100. A user may be able to inhale the volatilized component(s) of the aerosolizable material by drawing the volatilized component(s) from the heating zone 110. As the volatilized component(s) are removed from the heating zone 110 and the consumable 1, 2, air may be drawn into the heating zone 110 via the air inlet(s) of the apparatus 100.

In this embodiment, the heating zone 110 comprises a recess for receiving at least a portion of the consumable 1, 2. In other embodiments, the heating zone 110 may be other than a recess, such as a shelf, a surface, or a projection, and may require mechanical mating with the consumable 1, 2 in order to co-operate with, or receive, the consumable 1, 2. In this embodiment, the heating zone 110 is elongate, and is sized and shaped to accommodate the whole consumable 1, 2. In other embodiments, the heating zone 110 may be dimensioned to receive only a portion of the consumable 1, 2.

In some cases in use, substantially all of the amorphous solid is less than about 4 mm, 3 mm, 2 mm or 1 mm from the heater (i.e. the heatable element or the resistive heater). In some cases, the solid is disposed between about 0.010 mm and 2.0 mm from the heater, suitably between about 0.02 mm and 1.0 mm, suitably 0.1 mm to 0.5 mm. These minimum distances may, in some cases, reflect the thickness of a carrier that supports the amorphous solid. In some cases, a surface of the amorphous solid may directly abut the heater.

In some embodiments, the device 112 comprises an electrical power source, a resistive heater that is heated by passing electricity through the resistive heater, and a controller for controlling the passage of electricity through the resistive heater. The resistive heater is configured to apply heat energy to the heating zone 110, and thus to the consumable 1, 2 when the consumable is in the heating zone 110. The resistive heater may cause the heat energy to be applied to the aerosolizable material of the consumable 1, 2. In some embodiments, the resistive heater may project into the heating zone 110 so as to be located in the passageway 20 of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110. In some other embodiments, the resistive heater may be located radially outwards of the consumable 1, 2 when the consumable is in the heating zone 110. For example, the resistive heater may at least partially define the heating zone 110. In some embodiments, the device may comprise a first resistive heater that is in the passageway 20 of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110, and a second resistive heater that is located radially outwards of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110.

In some embodiments, such as that shown in FIG. 5, the device 112 comprises a magnetic field generator for generating a varying magnetic field for penetrating the heating zone 110 when the consumable 1, 2 is in the heating zone 110.

As discussed above, in some embodiments, the consumable comprises heating material for use in heating the aerosolizable material. In such embodiments, the magnetic field generator of the apparatus may be configured to generate a varying magnetic field that penetrates the heating material of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110.

In other embodiments, such as that shown in FIG. 5, the device 112 of the apparatus 100 comprises a heatable heating element 111, and the magnetic field generator is configured to generate a varying magnetic field that penetrates the heating element 111. In some embodiments, the heating element is located radially outwards of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110. For example, the heating element may at least partially define the heating zone 110. In other embodiments, such as that shown in FIG. 5, the heating element 111 projects into the heating zone 110. The heating element 111 may be insertable into the passageway 20 of the consumable 1, 2 in use. In some embodiments, such as that shown in FIG. 5, the heating element 111 enters the passageway 20 while the consumable 1, 2 is inserted into the heating zone 110. In other embodiments the apparatus may be configured so that the heating element 111 is movable relative to the heating zone 110 so as to project into the passageway 20 when the consumable 1, 2 is already located in the heating zone 110.

In some embodiments, the heating element 111 of the apparatus has an outer cross-sectional shape, and the innermost surface 1 b, 2 b of the hollow tube 1 a, 2 a of the consumable 1, 2 has an inner cross-sectional shape that matches the outer cross-sectional shape of the heating element 111. For example, the inner and outer cross-sectional shapes may be circular or may be non-circular, such as elliptical, polygonal, rectangular, square, triangular, corrugated, or star-shaped. In some embodiments, the heating element 111 of the apparatus and the innermost surface 1 b, 2 b of the hollow tube 1 a, 2 a of the consumable 1, 2 are relatively dimensioned so that the innermost surface abuts the heating element 111 in use, so as to increase the efficiency and effectiveness of heat energy transfer from the heating element 111 to the innermost surface. The innermost surface may be a close fit to, or a snug fit on, the heating element 111.

In this embodiment, the magnetic field generator comprises an electrical power source 113, a coil 114, a device 116 for passing a varying electrical current, such as an alternating current, through the coil 114, a controller 117, and a user interface 118 for user-operation of the controller 117.

The electrical power source 113 of this embodiment is a rechargeable battery. In other embodiments, the electrical power source 113 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains electricity supply.

The coil 114 may take any suitable form. In some embodiments, the coil 114 is a helical coil of electrically-conductive material, such as copper. In some embodiments, the coil is a flat coil. That is, the coil may be a two-dimensional spiral of electrically-conductive material, such as copper. In some embodiments, the coil 114 encircles the heating zone 110. In some embodiments, the coil 114 extends along a longitudinal axis that is substantially aligned with a longitudinal axis of the heating zone 110. The aligned axes may be coincident. Alternatively, the aligned axes may be parallel or oblique to each other.

In this embodiment, the device 116 for passing a varying current through the coil 114 is electrically connected between the electrical power source 113 and the coil 114. In this embodiment, the controller 117 also is electrically connected to the electrical power source 113, and is communicatively connected to the device 116 to control the device 116. More specifically, in this embodiment, the controller 117 is for controlling the device 116, so as to control the supply of electrical power from the electrical power source 113 to the coil 114. In this embodiment, the controller 117 comprises an integrated circuit (IC), such as an IC on a printed circuit board (PCB). In other embodiments, the controller 117 may take a different form. In some embodiments, the apparatus 100 may have a single electrical or electronic component comprising the device 116 and the controller 117. The controller 117 is operated in this embodiment by user-operation of the user interface 118. The user interface 118 may comprise a push-button, a toggle switch, a dial, a touchscreen, or the like. In other embodiments, the user interface 118 may be remote and connected to the rest of the apparatus 100 wirelessly, such as via Bluetooth.

In this embodiment, operation of the user interface 118 by a user causes the controller 117 to cause the device 116 to cause an alternating electrical current to pass through the coil 114. This causes the coil 114 to generate an alternating magnetic field. The coil 114 and the heating zone 110 of the apparatus 100 are suitably relatively positioned so that, when the consumable 1, 2, 3 is located in the heating zone 110, the varying magnetic field produced by the coil 114 penetrates the heating element 111 of the apparatus 100. When the heating material of the heating element 111 is electrically-conductive, this penetration causes the generation of one or more eddy currents in the heating material. The flow of eddy currents in the heating material against the electrical resistance of the heating material causes the heating material to be heated by Joule heating. When the heating material of the heating element 111 is a magnetic material, the orientation of magnetic dipoles in the heating material changes with the changing applied magnetic field, which causes heat to be generated in the heating material.

In some embodiments, the consumable 1, 2 comprises heating material and the coil 114 and the heating zone 110 of the apparatus 100 are suitably relatively positioned so that, when the consumable 1, 2 is located in the heating zone 110, the varying magnetic field produced by the coil 114 penetrates the heating material of the consumable 1, 2. In some embodiments, the apparatus 100 comprises the heating element 111, the heating element 111 comprises heating material, and the consumable 1, 2 also comprises heating material. In some such embodiments, the coil 114 and the heating zone 110 of the apparatus 100 may be suitably relatively positioned so that, when the consumable 1, 2 is located in the heating zone 110, the varying magnetic field produced by the coil 114 penetrates the heating material of the consumable 1, 2 and the heating material of the heating element 111.

The apparatus 100 of this embodiment comprises a temperature sensor 119 for sensing a temperature of the heating zone 110. The temperature sensor 119 is communicatively connected to the controller 117, so that the controller 117 is able to monitor the temperature of the heating zone 110. On the basis of one or more signals received from the temperature sensor 119, the controller 117 may cause the device 112 to adjust a characteristic of the varying or alternating electrical current passed through the coil 114 as necessary, in order to ensure that the temperature of the heating zone 110 remains within a predetermined temperature range. The characteristic may be, for example, amplitude or frequency or duty cycle. Within the predetermined temperature range, in use the aerosolizable material within a consumable located in the heating zone 110 is heated sufficiently to volatilize at least one component of the aerosolizable material 14 without combusting the aerosolizable material 14. Accordingly, the controller, and the apparatus 100 as a whole, is arranged to heat the aerosolizable material to volatilize the at least one component of the aerosolizable material without combusting the aerosolizable material. In some embodiments, the temperature range is about 50° C. to about 350° C., such as between about 100° C. and about 300° C., or between about 120° C. and about 350° C., or between about 140° C. and about 250° C., or between about 200° C. and about 270° C. In other embodiments, the temperature range may be other than one of these ranges. In some embodiments, the upper limit of the temperature range could be greater than 350° C. In some embodiments, the consumable may be non-combustible, for example in these ranges of temperatures. In some embodiments, the temperature sensor 119 may be omitted.

In some embodiments, the device 112 for causing heating of the aerosolizable material when the consumable is in the heating zone 110 is configured for heating different sections of the heating zone 110 independently of each other, such as by way of comprising independently-controllable heatable elements 111.

In some embodiments, the heating material of the consumable 1, 2, or of the heatable heating element 111 of the apparatus 100, is aluminum. However, in other embodiments, the heating material may comprise one or more materials selected from the group consisting of: an electrically-conductive material, a magnetic material, and a magnetic electrically-conductive material. In some embodiments, the heating material may comprise a metal or a metal alloy. In some embodiments, the heating material may comprise one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain-carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze. Other heating material(s) may be used in other embodiments.

In some embodiments, such as those in which the heating material comprises iron, such as steel (e.g. mild steel or stainless steel), or aluminum, the heating material may be coated to help avoid corrosion or oxidation of the heating material in use. Such coating may, for example, comprise nickel plating, gold plating, or a coating of a ceramic or an inert polymer.

In some embodiments, the consumable 1, 2 may comprise heating material that is partially or fully embedded in the aerosolizable material of the consumable 1, 2. In some embodiments, the aerosolizable material may comprise heating material. In some embodiments, the aerosolizable material may be free from heating material.

In some embodiments, the aerosolizable material comprises tobacco. However, in other embodiments, the aerosolizable material may consist of tobacco, may consist substantially entirely of tobacco, may comprise tobacco and aerosolizable material other than tobacco, may comprise aerosolizable material other than tobacco, or may be free from tobacco. In some embodiments, the aerosolizable material may comprise a vapor or aerosol forming agent or a humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol.

In some embodiments, the consumable is non-combustible. In some embodiments, the consumable is configured so as not to be combustible in use.

In some embodiments, once all, or substantially all, of the volatilizable component(s) of the aerosolizable material in the consumable 1, 2 has/have been spent, the user may remove the consumable 1, 2 from the heating zone of the apparatus 100 and dispose of the consumable 1, 2. The user may subsequently re-use the apparatus 100 with another of the consumables 1, 2. However, in other respective embodiments, the apparatus 100 and the consumable 1, 2 may be disposed of together once the volatilizable component(s) of the aerosolizable material has/have been spent.

In some embodiments, the consumable 1, 2 is sold, supplied or otherwise provided separately from the apparatus 100 with which the consumable 1, 2 is usable. However, in some embodiments, the apparatus 100 and one or more of the consumables 1, 2 may be provided together as a system, such as a kit or an assembly, possibly with additional components, such as cleaning utensils.

For the avoidance of doubt, where in this specification the term “comprises” is used in defining the invention or features of the invention, embodiments are also disclosed in which the invention or feature can be defined using the terms “consists essentially of” or “consists of” in place of “comprises”. Reference to a material “comprising” certain features means that those features are included in, contained in, or held within the material.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration and example various embodiments in which the claimed invention may be practiced and which provide for superior consumables for use with apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, systems comprising such a consumable and such apparatus, and methods of manufacturing a hollow tube for use in or as such a consumable. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed and otherwise disclosed features. It is to be understood that advantages, embodiments, examples, functions, features, structures and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist in essence of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. The disclosure may include other inventions not presently claimed, but which may be claimed in future. 

1. A consumable for use with apparatus for heating aerosolizable material to volatilise at least one component of the aerosolizable material, the consumable comprising a hollow tube comprising a wound structure comprising aerosolizable material.
 2. The consumable of claim 1, wherein the wound structure is a helically wound structure.
 3. The consumable of claim 1, wherein the wound structure defines at least part of a surface of the consumable.
 4. The consumable of claim 3, wherein the surface is an innermost surface of the consumable.
 5. The consumable of claim 1, wherein the wound structure comprises corrugations, embossing or debossing.
 6. The consumable of claim 1, wherein the wound structure forms a layer of the hollow tube, and the hollow tube comprises one or more further layers.
 7. The consumable of claim 5, wherein the wound structure forms a layer of the hollow tube, wherein the hollow tube comprises one or more further layers, and wherein the hollow tube comprises one or more aerosol flow paths defined by and between the corrugations, embossing or debossing of the structure comprising aerosolizable material and at least one of the one or more further layers.
 8. The consumable of claim 1, wherein the hollow tube comprises a barrier layer that defines at least part of a surface of the consumable.
 9. The consumable of claim 1, further comprising a heating material that is heatable by penetration with a varying magnetic field.
 10. The consumable of claim 9, wherein the hollow tube comprises a layer comprising the heating material.
 11. The consumable of claim 9 or claim 10, when dependent directly or indirectly on claim 8, wherein the layer comprising the heating material is located between the barrier layer and the wound structure comprising aerosolizable material.
 12. The consumable of claim 6, wherein at least one of the one or more further layers comprises aerosolizable material.
 13. The consumable of claim 12, wherein the hollow tube comprises a layer comprising a heating material, wherein the layer comprising the heating material is located between the wound structure comprising aerosolizable material and the at least one further layer comprising aerosolizable material.
 14. The consumable of claim 6, wherein at least one of the one or more further layers comprises a flavorant or a sensate.
 15. The consumable of claim 1, wherein the aerosolizable material of the wound structure comprises an amorphous solid.
 16. A system for heating aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising: a consumable comprising a hollow tube comprising a wound structure comprising aerosolizable material; and an apparatus for heating the aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material, the apparatus comprising a heating zone for receiving the consumable, and a device for causing heating of the aerosolizable material when the consumable is in the heating zone.
 17. The system of claim 16, wherein the device comprises a magnetic field generator for generating a varying magnetic field for penetrating the heating zone when the consumable is in the heating zone.
 18. A method of manufacturing a hollow tube for use in or as a consumable for use with an apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material, the method comprising: winding a structure comprising aerosolizable material.
 19. The method of claim 18, wherein the winding comprises helically winding the structure comprising aerosolizable material.
 20. The method of claim 18, wherein the winding comprises winding the structure comprising aerosolizable material around a mandrel.
 21. The method of claim 20, further comprising applying the aerosolizable material to a material using the mandrel to form the structure.
 22. The method of claim 18, comprising winding a material while drawing the material from a supply, and applying the aerosolizable material to the material downstream of the supply.
 23. The method of claim 18, wherein the wound structure forms a layer of the hollow tube, and the method comprises winding one or more further layers.
 24. The method of claim 23, wherein at least one of the one or more further layers comprises a heating material that is heatable by penetration with a varying magnetic field.
 25. The method of claim 18, wherein winding the structure comprising aerosolizable material comprises winding the structure comprising aerosolizable material to form an innermost surface of the hollow tube.
 26. The method of claim 18, wherein the structure comprising aerosolizable material consists of the aerosolizable material, or comprises a carrier with the aerosolizable material on a surface of the carrier or impregnated in the carrier.
 27. The method of claim 18, wherein the aerosolizable material of the structure comprises an amorphous solid. 